light DODGE RAM 1500 1998 2.G Owner's Manual

(2) Assemble clutch discs into packs and secure
disc packs with retaining clips (Fig. 49).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(3) Position differential case on the Holding Fix-
ture 8136.
(4) Position assembled clutch disc packs on the
side gear hubs.
(5) Install clutch pack and side gear in the differ-
ential case (Fig. 50).
CAUTION: Verify clutch pack retaining clips are in
position and seated in case pockets.(6) Install lubricated disc from Trac-LoktTool Kit
8139 in lower side gear.
(7) Install upper side gear and clutch disc pack
(Fig. 51).
CAUTION: Verify clutch pack retaining clips are in
position and seated in case pockets.
(8) Hold assembly in position and install threaded
disc from tool kit into top side gear.
(9) Install forcing screw from Trac-LoktTool Kit
C-4487 and tighten screw to slightly compress clutch
disc.
Fig. 49 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 50 CLUTCH PACK AND SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
3 - 104 REAR AXLE-91/4DR
DIFFERENTIAL-TRAC-LOK (Continued)

(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.
(11) Rotate case with turning bar until pinion
mate shaft holes in pinion gears align with holes in
case.
NOTE: It may be necessary to slightly tighten the
forcing screw in order to install the pinion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw, Discs and Threaded
Adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft screw.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove differential bearings from the case
with Puller/Press C-293-PA and Adapters C-293-47
and Plug C-293-3 (Fig. 52).
Fig. 51 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 52 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
DRREAR AXLE - 9 1/4 3 - 105
DIFFERENTIAL-TRAC-LOK (Continued)

(3) Install front pinion bearing cup (Fig. 63) with
Installer D-129 and Handle C-4171 and verify cup is
seated.
(4) Lubricate and install front pinion bearing into
the housing.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-4076-B
and Handle C-4735-1 (Fig. 64).
(6) Install pinion depth shim (Fig. 65) on the pin-
ion gear shaft.
(7) Install rear bearing on the pinion (Fig. 66) with
Installer C-3095-A and a press.
Fig. 63 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 64 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
3 - HOUSING
Fig. 65 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 66 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
DRREAR AXLE - 9 1/4 3 - 109
PINION GEAR/RING GEAR/TONE RING (Continued)

REAR AXLE - 10 1/2 AA
TABLE OF CONTENTS
page page
REAR AXLE - 10 1/2 AA
DIAGNOSIS AND TESTING...............112
REMOVAL............................115
INSTALLATION........................116
ADJUSTMENTS.......................116
SPECIFICATIONS......................120
SPECIAL TOOLS.......................120
AXLE SHAFTS
REMOVAL............................124
INSTALLATION........................124
AXLE BEARINGS
REMOVAL............................125
INSTALLATION........................125
PINION SEAL
REMOVAL............................126
INSTALLATION........................126
DIFFERENTIAL
REMOVAL............................127DISASSEMBLY........................128
ASSEMBLY...........................129
INSTALLATION........................130
DIFFERENTIAL TRAC-RITE
DESCRIPTION........................131
OPERATION..........................131
DISASSEMBLY........................131
CLEANING...........................132
INSPECTION.........................132
ASSEMBLY...........................133
DIFFERENTIAL CASE BEARINGS
REMOVAL............................134
INSTALLATION........................134
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................134
INSTALLATION........................137
REAR AXLE - 10 1/2 AA
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly check for:
²Insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. The side gears are loaded dur-
ing turns. They usually do not cause noise during
straight-ahead driving when the gears are unloaded.
A worn pinion shaft can also cause a snapping or a
knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearingsusually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joint(s).
²Worn side-gear thrust washers.
²Worn pinion shaft bore.
3 - 112 REAR AXLE - 10 1/2 AADR

(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.
(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(12) Tighten bearing cap bolts to 115 N´m (85 ft.
lbs.).
(13) Tighten adjuster lock bolts to 33 N´m (24 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig. 9).
The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005-
0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern correct (Fig. 10). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
11). Decrease the backlash, by moving the ring closer
to the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 12).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 10 CORRECT CONTACT PATTERN
Fig. 11 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 118 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

(8)Install retainer ring with ring end in the key slot.
(9) Install new axle shaft gasket and install axle
shaft.
PINION SEAL
REMOVAL
(1) Remove axle shafts.
(2) Mark propeller shaft and pinion flange for
installation reference and remove shaft.
(3) Rotate pinion gear three or four times.
(4) Measure and record the amount of torque nec-
essary to rotate the pinion gear with an inch pound
torque wrench (Fig. 22).(5) Hold pinion flange with Flange Wrench 8979
(Fig. 23) and remove pinion flange nut and washer.
(6) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 24).
(7) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Installnewpinion seal with Installer 8896 and
Handle C-4171 (Fig. 25).
(2) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer andnewpinion nut.
Fig. 21 HUB NUT SOCKET
1 - SOCKET
2 - TORQUE WRENCH
Fig. 22 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 23 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
Fig. 24 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
3 - 126 REAR AXLE - 10 1/2 AADR
AXLE BEARINGS (Continued)

INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubricate differential case bearing.
(3) Install differential case with bearings cups into
the housing.
NOTE: A light coat of grease on the cups will hold
them in place during installation.
(4) Install bearing caps and bolts (Fig. 36). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
(5) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.
(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings6 Adjuster Holes
²Original Bearings4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 165 N´m (122 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 37).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).
Fig. 36 CASE BEARING CAP
1 - DIFFERENTIAL HOUSING
2 - BEARING CAP
3 - ADJUSTERFig. 37 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 130 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL (Continued)

(6) Remove six pinion gears (Fig. 41).
(7) Remove remaining side gear thrust washer and
spacer.
(8) Remove remaining three pinion brake shoes.
CLEANING
Clean the differential case and gears with light oil
or a lint free cloth.
NOTE: Never use water, steam, kerosene or gaso-
line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be
smoothed with 400 grit emery cloth and polished
out with crocus cloth.
(1) Inspect pinion gears teeth for chips and cracks
(Fig. 42).
(2) Inspect pinion gears shafts and brake shoes for
scratches, flat-spots or worn (Fig. 42).(3) Inspect side gears teeth for chips and cracks
(Fig. 43).
(4) Inspect pinion and side gear bores for scratches
(Fig. 44).
NOTE: If any damage is found the differential must
be replaced as an assembly. Individual components
can not be replaced separately.
Fig. 41 PINION GEARS
1 - PINION GEARS
2 - SIDE GEAR
Fig. 42 PINION GEAR AND BRAKE SHOE
1 - BRAKE SHOES
2 - PINION GEAR
3 - PINION SHAFT
Fig. 43 SIDE GEARS
1 - THRUST WASHERS
2 - SPACER
3 - SIDE GEARS
3 - 132 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL TRAC-RITE (Continued)

(5) Installnewcollapsible spacer (Fig. 59).
(6) Lubricate pinion and bearings.
(7) Install pinion into the housing and place front
pinion bearing onto the pinion shaft. Draw the pinion
shaft into the front bearing with Installer 8981 (Fig.
60).(8) Installnewpinion seal (Fig. 61) with Installer
8896 and Handle C-4171.
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold the pinion and lightly tap the pinion
flange onto the pinion, until a few threads are show-
ing.
(11) Install pinion flange washer andnewpinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
(Fig. 62) and tighten pinion nut until pinion end play
is taken up.
Fig. 59 COLLAPSIBLE SPACER
1 - COLAPSIBLE SPACER
2 - PINION GEAR
3 - REAR PINION BEARING
Fig. 60 PINION GEAR INSTALLER
1 - INSTALLER
2 - DIFFERENTIAL HOUSING
Fig. 61 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 62 FLANGE WRENCH
1 - FLANGE WRENCH
2 - PINION FLANGE
3 - 138 REAR AXLE - 10 1/2 AADR
PINION GEAR/RING GEAR/TONE RING (Continued)

REAR AXLE - 11 1/2 AA
TABLE OF CONTENTS
page page
REAR AXLE - 11 1/2 AA
DIAGNOSIS AND TESTING...............140
REMOVAL............................143
INSTALLATION........................144
ADJUSTMENTS.......................144
SPECIFICATIONS......................148
SPECIAL TOOLS.......................148
AXLE SHAFTS
REMOVAL............................152
INSTALLATION........................152
AXLE BEARINGS
REMOVAL............................152
INSTALLATION........................153
PINION SEAL
REMOVAL............................153
INSTALLATION........................154
DIFFERENTIAL
REMOVAL............................155DISASSEMBLY........................155
ASSEMBLY...........................156
INSTALLATION........................157
DIFFERENTIAL TRAC-RITE
DESCRIPTION........................158
OPERATION..........................158
DISASSEMBLY........................158
CLEANING...........................160
INSPECTION.........................160
ASSEMBLY...........................161
DIFFERENTIAL CASE BEARINGS
REMOVAL............................161
INSTALLATION........................161
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................162
INSTALLATION........................164
REAR AXLE - 11 1/2 AA
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly check for:
²Insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. The side gears are loaded dur-
ing turns. They usually do not cause noise during
straight-ahead driving when the gears are unloaded.
A worn pinion shaft can also cause a snapping or a
knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearingsusually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joint(s).
²Worn side gear thrust washers.
²Worn pinion shaft bore.
3 - 140 REAR AXLE - 11 1/2 AADR